Batca FUSION 4 FZ-3 User manual

www.batcatness.com Fusion 4 Lower Body Station
May 2021
Serial Number Here
Date of Purchase
FZ-3 Fusion 4 Lower Body Unit

Batca Fitness Systems 2Fusion 4 Lower Body Station
Page
Instructions 2
Hardware Blister Packs 3-6
Main Frame Assembly 7-11
Cable Routing 12-15
Upholstery 16-17
Leg Press Option 18-22
Cable Arms Cable Routing 21-22
Page
Cable Comparison 23
Cable Tension and Adjustments 24-25
Final Assembly and Troubleshooting 26
Maintenance 27
Warranty 28
Floor plan Layout 29-30
Congratulations on the purchase of your new Batca Fusion 4 Lower Body Unit. This gym
will provide you with a lifetime of enjoyment to meet your strength training needs. Batca
Fitness Systems strives to build the best quality gyms and to package these gyms in such a way
to avoid any damage during shipping.
In order to get started with your assembly you should rst familiarize yourself with this
manual. It is recommended that you read through each step thoroughly before you begin.
Begin by opening your boxes and separating all of your parts. Verify that all parts are accounted
for and have no damage. When all parts are accounted for, you may begin your assembly.
Some items may have been pre-assembled for your convenience. Please note that hardware
quantities shown reect total quantities for your gym and may not reect actual quantities in
each bag. Assemble your gym on a solid level surface. This will ensure the best possible
performance, function, and safety for the gym and your workout.
Assemble your gym according to the step by step instructions found in this manual. Failure
to do so will void your warranty and may result in personal injury. After assembly, you should
check each station to ensure correct operation. If a problem arises, recheck your assembly with
these instructions to verify correct assembly. If you are unable to correct a problem or have
questions with your assembly please contact your authorized Batca dealer.
Batca Fitness Systems has built this gym to give you a safe, effective and enjoyable
workout. However, there is a risk assumed by individuals who use this type of equipment. It is
very important that all warnings and instructions are read and followed before beginning any
exercise program.
It is also very important to read and follow the preventative maintenance schedule
described in this manual. If any of the warning labels or stickers are worn, faded, torn,
scratched or missing they should be replaced immediately.
WARNING: There is a risk assumed by individuals who use this type of equipment. To
minimize risk always follow these rules.
1)It is essential that you consult with your physician before beginning any exercise program.
2)Inspect equipment before each use for loose, worn, or frayed parts (including cables, nuts
and bolts). Replace parts at rst signs of wear (use only genuine BATCA replacement parts).
Use of equipment that is damaged, worn, frayed or not completely assembled on a solid,
level surface may result in injury.
3)Make sure all adjustment pins are fully engaged before using equipment.
4)Keep all parts of the body and clothing outside the path of any moving parts of the gym. Be
alert to the possibility of injury. Do not be careless.
5)Minors and children should not be allowed to play on or around this gym.
6)If you have any questions on proper use or maintenance of this gym, do not hesitate to call
your local BATCA FITNESS SYSTEMS distributor or BATCA FITNESS SYSTEMS at (919) 255-
1233. www.batcatness.com
Table of Contents
Instructions
Warning

www.batcatness.com 3Fusion 4 Lower Body Station
Tools Required
• 9/16” Wrench/Ratchet
• 1/2” Wrench/Rachet
• Metric Allen Wrench Set (M10, M8, M6,
M4)
• Utility Knife
• 3/4” Wrench
• Tape Measure
• Snap Ring Pliers
Hardware Blister Packs

Batca Fitness Systems 4Fusion 4 Lower Body Station
Hardware Blister Packs

www.batcatness.com 5Fusion 4 Lower Body Station
Hardware Blister Packs

Batca Fitness Systems 6Fusion 4 Lower Body Station
FZ-4 Leg Press Hardware Blister Pack

www.batcatness.com 7Fusion 4 Lower Body Station
Item # Part # Description Qty
1BFM-10747 Right Vertical Support 1
2BFM-10765 Middle Base 1
3BFM-10593 Rear Base 1
4BFM-10744 Upper Frame 1
5BFM-10769 Large Flat Leveler 2
45 BFP-52394 SHCS 3/8”-16 x 2 1/2 1
46 BFP-51653 SHCS 3/8”-16 x 1 1/4 2
47 BFP-51799 SHCS 3/8”-16 x 5” 1
48 BFP-51756 SHCS 3/8"-16 X 5 1/4" 2
73 BFH-50146 3/8” Flat Washer 11
74 BFH-50157 3/8” Nylock 5
75 BFH-50147 3/8” Lock Washer 1
Step 1:
Note: Please Position Hardware in the same direction as shown in the figure. This will
make future steps easier to assemble
PLEASE READ AND FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR PROPER INSTALLATION.
All Flat Washers and Nylocks are 3/8” unless otherwise noted. Anywhere a washer is against the
round side of a tube there is to be a 3/8” CURVED WASHER instead of a 3/8” FLAT WASHER.
DO NOT TIGHTEN BOLTS UNTIL NEXT STEP

Batca Fitness Systems 8Fusion 4 Lower Body Station
Item # Part # Description Qty
1BFM-10747 Left Vertical Support 1
6BFM-51490 Guide Rod Holder 1
7BFM-51082 Shroud 1
125 BFM-52410 Front Shroud 1
8BFM-51051 Guide Rod 2
9BFM-50256 Weight Plate 19
10 BFM-50529 Rubber Donut 2
11 BFM-10299 Top Weight Plate 1
35 BFM-51173 Weight Stack Pin 1
Item # Part # Description Qty
45 BFP-52394 SHCS 3/8”-16 x 2-1/2” 1
47 BFP-51799 SHCS 3/8”-16 x 5” 3
49 BFH-50630 FHSCS 3/8"-16 x 3/4” 2
56 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
51 BFH-52340 SHCS 3/8”-16 x 3/4” 2
73 BFH-50146 3/8” Flat Washer 13
74 BFH-50157 3/8” Nylock 3
75 BFH-50147 3/8” Lock Washer 7
Assemble Last
(see note)
BHSCS
3/8” X 1/2”
(Qty=4)
This 3/8” Nylock and Flat
Washer are from step 1.
DO NOT remove the nylock or
install the Left Vertical Support
until the Weight Stack and the
Shrouds have been completely
assembled.
All Flat Washers and
Nylocks are 3/8” unless
otherwise noted.
Step 2: Make Sure All Bolts are Tightened Before Moving on

www.batcatness.com 9Fusion 4 Lower Body Station
Item # Part # Description Qty
12 BFM-10581 Leg Extension Curl Frame 1
13 BFM-51143 8” Anti Deection Plate 1
52 BFH-50144 FHSCS 3/8”-16 x 1” 2
53 BFP-52396 SHCS 3/8”-16 x 5 1/2” 2
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 4
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 3: Make Sure All Bolts are Tightened Before Moving On

Batca Fitness Systems 10 Fusion 4 Lower Body Station
Item # Part # Description Qty
14 BFM-10141 Knee Alignment Roller 1
15 BFM-10584 Leg Extension Shaft 1
16 BFM-10585 Leg Extension Cam Assembly 1
17 BFM-50222 Axle 1
54 BFH-50165 1” Snap Ring 1
55 BFH-50337 Wavy Washer 2
68 BFP-52420 BHSCS 3/8"-16 x 2” 1
57 BFM-50245 FHSCS 5/16” x 1” 2
74 BFH-50157 3/8" Nylock 1
BHSCS 3/8” x2”
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 4: Make Sure All Bolts are Tightened Before Moving On

www.batcatness.com 11 Fusion 4 Lower Body Station
Item # Part # Description Qty
18 BFM-10742 Leg Extension Arm Assembly 1
19 BFM-10587 Knee Hold Down Assembly 1
20 BFM-51094 Axle 1
31 BFL-50274 Knee Hold Down Adjustment Plate 1
32 BFL-50211 T-Shaped Plate 1
54 BFH-50165 1” Snap Ring 1
55 BFH-50337 Wavy Washer 1
58 BFP-51747 SHCS 3/8”-16 x 3” 3
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
126 BFM-52422 Red Pivot Point Cap 1
127 BFH-50620 BHSCS 3/8” x 1” 1
T-Shaped
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 5: Make Sure All Bolts are Tightened Before Moving On

Batca Fitness Systems 12 Fusion 4 Lower Body Station
Item # Part # Description Qty
21 BFM-10611 Criss-Cross Free Floater 1
41 CAB-13022 Weight Stack to Cable Tie Out 1
59 BFH-50174 4 1/2” Pulley 1
60 BFH-50173 3 1/2” Pulley 2
61 BFH-50267 5/16” Nylock 1
62 BFP-51752 SHCS 3/8”-16 x 2 1/4 3
63 BFH-50250 1-1/4” Shoulder Bolt 1
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
71 5/8”
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Cable Routing
Step 6: Make Sure All Bolts are Tightened Before Moving On
Note: Each Cable with a threaded bolt
on either end must be threaded at
least 1/2” into its attachment.

www.batcatness.com 13 Fusion 4 Lower Body Station
Item # Part # Description Qty
22 BFM-10610 Lower Pulley Holder 2
42 CAB-13028 Fusion Free Floater Cable 1
59 BFH-50174 4 1/2” Pulley 3
62 BFP-51752 SHCS 3/8”-16 x 2 1/4” 3
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
86 5/16”
CAB-13028
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 7: Make Sure All Bolts are Tightened Before Moving On

Batca Fitness Systems 14 Fusion 4 Lower Body Station
Item # Part # Description Qty
23 BFM-10612 Cable Tie Out Plate 1
33 BFL-50203 Pulley Holder Connector Plate 1
43 CAB-13026 Fusion Cable Tie Out 1
48 BFP-51756 SHCS 3/8”-16 x 5 1/4” 2
73 BFH-50146 3/8” Flat Washer 4
74 BFH-50157 3/8” Nylock 2
22 5/8”
Note: The Orientation of the
Pulley Holder Connector
Plate should reect this
drawing. If not installed
correctly, the machine will
not function properly.
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 8: If Leg Press Was Purchased Skip This Step and Continue To Step 9. Make Sure All Bolts
Are Tightened Before Moving Forward
Note: Each Cable with a threaded bolt
on either end must be threaded at
least 1/2” into its attachment.

www.batcatness.com 15 Fusion 4 Lower Body Station
Item # Part # Description Qty
24 BFM-50505 3 1/2” Pulley Cover 1
25 BFH-52553 5/16” Pulley Spacer 1
34 BFL-50221 3 1/2” Double Pulley Cover 2
44 CAB-13029 Fusion Leg Extension Cable 1
45 BFP-52394 SHCS 3/8”-16 x 2 1/2” 1
60 BFH-50173 3 1/2” Pulley 5
61 BFM-50267 5/16” Nylock 1
62 BFP-51752 SHCS 3/8”-16 x 2 1/4 3
63 BFH-50250 1 1/4 Shoulder Bolt 1
64 BFP-52397 SHCS 3/8”-16 x 1 3/4” 1
73 BFH-50146 3/8” Flat Washer 7
74 BFH-50157 3/8” Nylock 5
75 BFH-50147 3/8” Lock Washer 4
91 1/4”
CAB-13029
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 9: Make Sure All Bolts are Tightened Before Moving On
If you have adjusted the cable system
and it appears your cable may be too
short or the Free Floating Pulleys directly
behind the back pad of the leg
extension/leg curl station are not at the
same level (one appears much lower
than the other), please double check the
orientation of the Pulley Holder
Connector Plate. It should reect this
drawing. There is a spacer welded to the
Pulley Holder Connector Plate. The
spacer should be facing away from the
machine if installed properly.
• Position the cable guard tab on the Pulley
Cover so that the tab prevents the cable
from coming out of it’s track on the 3
1/2” Pulley. An example of this
positioning can be seen in the gure to
the above. The cable guard tab should be
positioned so that it is in the middle of
the cable wrap on the 3 1/2” Pulley,
between points “A” and “B”. This will
allow better protection and prevent the
cable from rubbing the cable guard tab.

Batca Fitness Systems 16 Fusion 4 Lower Body Station
Item # Part # Description Qty
26 BFM-10588 Knee Hold Down Handle 1
27 BFM-51382 6” Counter Weight 1
36 BFU-10121 7” Upholstery Roller 4
39 BFU-10122 Large Upholstery Roller 1
64 BFP-52397 SHCS 3/8”-16 x 1-3/4 1
66 BFH-50622 Upholstery Cap 4
67 BFH-50221 3” Plastic Washer 4
99 BFP-52430 BHSCS 3/8”-16 x 3/4” 4
69 BFH-50204 Curved Washer 4
70 BFP-52524 SHCS 3/8”-16 x 6 1/4” 1
73 BFH-50146 3/8” Flat Washer 1
74 BFH-50157 3/8” Nylock 1
75 BFH-50147 3/8” Lock Washer 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 10: Make Sure All Bolts are Tightened Before Moving On

www.batcatness.com 17 Fusion 4 Lower Body Station
Item # Part # Description Qty
28 BFM-10768 Right Handle 1
29 BFM-10767 Left Handle 1
30 BFM-10580 Back Chrome Adjusment 1
36 BFP-52130 Large Bottom Pad 1
37 BFP-52137 Head Pad 1
38 BFP-52136 Back Pad With Lumbar 1
46 BFP-51653 SHCS 3/8"-16 X 1 1/4” 2
58 BFP-51747 SHCS 3/8”-16 x 3” 2
71 BFP-51750 SHCS 3/8"-16 X 2 3/4” 2
72 BFP-51748 SHCS 3/8"-16 X 3 1/4” 2
73 BFH-50146 3/8” Flat Washer 10
74 BFH-50157 3/8” Nylock 2
75 BFH-50147 3/8” Lock Washer 6
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 11: Make Sure All Bolts are Tightened Before Moving On

Batca Fitness Systems 18 Fusion 4 Lower Body Station
Item # Part # Description Qty
76 BFM-10575 Leg Press Connector 1
77 BFM-11042 Leg Press Frame 1
78 BFM-11034 Four Bar 2
79 BFM-52449 Four Bar Spacer 2
80 BFM-11035 Leg Press Pivot Arm 1
81 BFP-51844 1” Shaft 2
82 BFP-51846 3/4” Shaft 2
100 BFH-50146 3/8" Flat Washer (Black) 4
101 BFH-50157 3/8"-16 Nylock (Black) 2
97 BFP-51756 SHCS 3/8"-16 X 5 1/4" P5 2
FZ-4 Leg Press Option
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 12: Make Sure All Bolts are Tightened Before Moving On

www.batcatness.com 19 Fusion 4 Lower Body Station
Item # Part # Description Qty
83 BFM-11036 Leg Press Foot Plate 1
84 BFM-11040 Right Handle 1
85 BFM-11041 Left Handle 1
86 BFM-10106 Back Adjustment Tube 1
87 BFP-51696 Small Aluminum End Cap 2
90 BFP-51700 BHSCS 3/8” x 1” 4
105 BFP-51747 SHCS 3/8” x 3” 2
100 BFH-50146 3/8" Flat Washer (Black) 6
101 BFH-50157 3/8"-16 Nylock (Black) 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 13: Make Sure All Bolts are Tightened Before Moving On

Batca Fitness Systems 20 Fusion 4 Lower Body Station
Item # Part # Description Qty
104 BFP-52136 Back Pad with Lumbar 1
103 BFP-52130 Large Bottom Pad 1
92 BFP-51653 SHCS 3/8” x 1 1/4” 2
96 BFP-51750 SHCS 3/8” x 2 3/4” 2
99 BFH-50147 3/8” Lock Washer 4
100 BFH-50146 3/8" Flat Washer (Black) 4
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 14: Make Sure All Bolts are Tightened Before Moving On